Aggie Chocolate Factory Chocolate Bar Foil Folder

Team: Matt Berardi, Daniel Humble, Maggie Lea, Alessa Love

Sponsor: Aggie Chocolate Factory

Project Description

The Aggie Chocolate Factory would like to improve the chocolate foiling process to enhance efficiency and allot more labor towards the actual production of the chocolate bars.

Requirements:

  • Faster than current process
  • Appealing
  • Inexpensive
  • Durable and low maintenance

Constraints:

  • Able to foil standard rectangle bar
  • Food grade
  • Workspace operable
  • Reduced foil time
  • Appealing folds
  • Minimal number of operators

Design Description

computer model of design
  • The jig designed by the team is used to fold the short edges of the foil.
  • Then corners can be folded by hand with assistance of the jig.
  • Finally, the operator folds the long edges of the foil by hand.

Folding process:

place bar

place bar

fold short edges

fold short edges

pinch four corners

pinch four corners

open hinges, finish corner folds

open hinges, finish corner folds

fold long edges

fold long edges

done!

done!

Performance Review

Tests to verify system performance :

  Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Avg Time
Maggie 23.19 21.26 22.75 19.65 15.34 20.44
AJ 14.80 21.20 15.63 11.07 9.82 14.50
Dan 16.32 21.01 17.45 20.63 19.28 18.94
Matt 14.05 8.78 15.74 12.51 8.37 11.89
Threshold 60         16.44
  • Time to fold
  • Appearance
  • Ease of operation
chocolate bar foiled top
chocolate bar foiled bottom
person using the foil folder

Conclusion

Lessons Learned:

  • Simple is best! – The design progressed from being complicated to more simplified while still improving performance
    Earliest design
    Early design
    Mid design
    Final design

Recommended Future Work:

  • Finalize metal version of prototype for longevity
  • Explore options for automating the design with electronics
  • Adjust system for other bar sizes
  • Eat more chocolate